Synthesis of chabazite-containing molecular sieves and their use in the conversion of oxygenates to olefins

ABSTRACT

In a method of synthesizing a silicoaluminophosphate molecular sieve having 90%+CHA framework type character, a reaction mixture is prepared comprising first combining a reactive source of aluminum with a reactive source of phosphorus to form a primary mixture that is aged. A reactive source of silicon and a template for directing the formation of the molecular sieve can then be added to form a synthesis mixture. Crystallization is then induced in the synthesis mixture. Advantageously, (i) the source of silicon comprises an organosilicate, (ii) the source of phosphorus optionally comprises an organophosphate, and (iii) the crystallized silicoaluminophosphate molecular sieve has a crystal size distribution such that its average crystal size is not greater than 5 μm. The molecular sieve can then preferably be used in a hydrocarbon (oxygenates-to-olefins) conversion process.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a divisional of U.S. application Ser. No. 12/477,750 filed on Jun. 3, 2009, now U.S. Pat. No. 8182780, and is related to, and claims priority to, U.S.S.N. 61/083,775, U.S.S.N. 61/083,765, U.S.S.N. 61/083,760, and U.S.S.N. 61/083,749, each filed on Jul. 25, 2008, U.S. patent application Ser. No. 12/477,700, U.S. patent application Ser. No. 12/477,826, and U.S. patent application Ser. No. 12/477,808, each filed on Jun. 3, 2009, and entitled, “Synthesis of Chabazite-Containing Molecular Sieves and Their Use in the Conversion of Oxygenates to Olefins,” the entire disclosures of each of which are hereby incorporated by reference herein.

FIELD OF THE INVENTION

This invention relates to the synthesis of chabazite-type containing molecular sieves and their use in the conversion of oxygenates, particularly methanol, to olefins, particularly ethylene and/or propylene.

BACKGROUND OF THE INVENTION

The conversion of oxygenates to olefins (OTO) is currently the subject of intense research because it has the potential for replacing the long-standing steam cracking technology that is today the industry-standard for producing world scale quantities of ethylene and propylene. The very large volumes involved suggest that substantial economic incentives exist for alternate technologies that can deliver high throughputs of light olefins in a cost efficient manner. Whereas steam cracking relies on non-selective thermal reactions of naphtha range hydrocarbons at very high temperatures, OTO exploits catalytic and micro-architectural properties of acidic molecular sieves under milder temperature conditions to produce high yields of ethylene and propylene from methanol.

Current understanding of the OTO reactions suggests a complex sequence in which three major steps can be identified: (1) an induction period leading to the formation of an active carbon pool (alkyl-aromatics), (2) alkylation-dealkylation reactions of these active intermediates leading to products, and (3) a gradual build-up of condensed ring aromatics. OTO is therefore an inherently transient chemical transformation in which the catalyst is in a continuous state of change. The ability of the catalyst to maintain high olefin yields for prolonged periods of time relies on a delicate balance between the relative rates at which the above processes take place. The formation of coke-like molecules is of singular importance because their accumulation interferes with the desired reaction sequence in a number of ways. In particular, coke renders the carbon pool inactive, lowers the rates of diffusion of reactants and products, increases the potential for undesired secondary reactions and limits catalyst life.

Over the last two decades, many catalytic materials have been identified as being useful for carrying out the OTO reactions. Crystalline molecular sieves are the preferred catalysts today because they simultaneously address the acidity and morphological requirements for the reactions. Particularly preferred materials are eight-membered ring aluminosilicates, such as those having the chabazite (CHA) framework type, as well as aluminophosphates (AlPOs) and silicoaluminophosphates (SAPOs) of the CHA framework type, such as SAPO-34.

Chabazite is a naturally occurring zeolite with the approximate formula Ca₆Al₁₂Si₂₄O₇₂. Three synthetic forms of chabazite are described in “Zeolite Molecular Sieves”, by D. W. Breck, published in 1973 by John Wiley & Sons, the complete disclosure of which is incorporated herein by specific reference. The three synthetic forms reported by Breck are Zeolite “K-G”, described in J. Chem. Soc., p. 2822 (1956), Barrer et al; Zeolite D, described in British Patent No. 868,846 (1961); and Zeolite R, described in U.S. Pat. No. 3,030,181 (1962). Zeolite K-G zeolite has a silica:alumina mole ratio of 2.3:1 to 4.15:1, whereas zeolites D and R have silica:alumina mole ratios of 4.5:1 to 4.9:1 and 3.45:1 to 3.65:1, respectively.

In U.S. Pat. No. 4,440,871, the synthesis of a wide variety of SAPO materials of various framework types is described with a number of specific examples. Also disclosed are a large number of possible organic templates, with some specific examples. In the specific examples a number of CHA framework type materials are described. The preparation of SAPO-34 is reported, using tetraethylammonium hydroxide (TEAOH), or isopropylamine, or mixtures of TEAOH and dipropylamine (DPA) as templates. Also disclosed is a specific example that utilizes cyclohexylamine in the preparation of SAPO-44. Although other template materials are described, there are no other templates indicated as being suitable for preparing SAPO's of the CHA framework type.

U.S. Pat. No. 6,162,415 discloses the synthesis of a silicoaluminophosphate molecular sieve, SAPO-44, which has a CHA framework type in the presence of a directing agent comprising cyclohexylamine or a cyclohexylammonium salt, such as cyclohexylammonium chloride or cyclohexylammonium bromide.

Silicoaluminophosphates of the CHA framework type with low silicon contents are particularly desirable for use in the methanol-to-olefins process. Thus, Wilson, et al., Microporous and Mesoporous Materials, 29, 117-126, 1999 report that it is beneficial to have lower Si content for methanol-to-olefins reaction, in particular because low Si content has the effect of reducing propane formation and decreasing catalyst deactivation.

U.S. Pat. No. 6,620,983 discloses a method for preparing silicoaluminophosphate molecular sieves, and in particular low silica silicoaluminophosphate molecular sieve having a Si/Al atomic ratio of less than 0.5, which process comprises forming a reaction mixture comprising a source of aluminum, a source of silicon, a source of phosphorus, at least one organic template, at least one compound which comprises two or more fluorine substituents and capable of providing fluoride ions, and inducing crystallization of the silicoaluminophosphate molecular sieve from the reaction mixture. Suitable organic templates are said to include one or more of tetraethyl ammonium hydroxide, tetraethyl ammonium phosphate, tetraethyl ammonium fluoride, tetraethyl ammonium bromide, tetraethyl ammonium chloride, tetraethyl ammonium acetate, dipropylamine, isopropylamine, cyclohexylamine, morpholine, methylbutylamine, morpholine, diethanolamine, and triethylamine In the Examples, crystallization is conducted by heating the reaction mixture to 170° C. over 18 hours and then holding the mixture at this temperature for 18 hours to 4 days.

U.S. Pat. No. 6,793,901 discloses a method for preparing a microporous silicoaluminophosphate molecular sieve having the CHA framework type, which process comprises (a) forming a reaction mixture comprising a source of aluminum, a source of silicon, a source of phosphorus, optionally at least one source of fluoride ions and at least one template containing one or more N,N-dimethylamino moieties, (b) inducing crystallization of the silicoaluminophosphate molecular sieve from the reaction mixture, and (c) recovering silicoaluminophosphate molecular sieve from the reaction mixture. Suitable templates are said to include one or more of N,N-dimethylethanolamine, N,N-dimethylbutanolamine, N,N-dimethylheptanolamine, N,N-dimethylhexanolamine, N,N-dimethylethylenediamine, N,N-dimethylpropylenediamine, N,N-dimethylbutylene-diamine, N,N-dimethylheptylenediamine, N,N-dimethylhexylenediamine, or dimethyl-ethylamine, dimethylpropylamine, dimethyl-heptylamine, and dimethylhexylamine. When conducted in the presence of fluoride ions, the synthesis is effective in producing low silica silicoaluminophosphate molecular sieves having a Si/Al atomic ratio of from 0.01 to 0.1. In the Examples, crystallization is conducted by heating the reaction mixture to 170 to 180° C. for 1 to 5 days.

U.S. Pat. No. 6,835,363 discloses a process for preparing microporous crystalline silicoaluminophosphate molecular sieves of CHA framework type, the process comprising: (a) providing a reaction mixture comprising a source of alumina, a source of phosphate, a source of silica, hydrogen fluoride and an organic template comprising one or more compounds of formula (I): (CH₃)₂N—R—N(CH₃)₂ where R is an alkyl radical of from 1 to 12 carbon atoms; (b) inducing crystallization of silicoaluminophosphate from the reaction mixture; and (c) recovering silicoaluminophosphate molecular sieve. Suitable templates are said to include one or more of the group consisting of: N,N,N′,N′-tetramethyl-1,3-propane-diamine, N,N,N′,N′-tetramethyl-1,4-butanediamine, N,N,N′,N′-tetramethyl-1,3 -butanediamine, N,N,N′,N′-tetramethyl-1,5-pentanediamine, N,N,N′,N′-tetramethyl-1,6-hexanediamine, N,N,N′,N′-tetramethyl-1,7-heptanediamine, N,N,N′,N′-tetramethyl-1,8-octanediamine, N,N,N′,N′-tetramethyl-1,9-nonanediamine N,N,N′,N′-tetramethyl-1,10-decanediamine, N,N,N′,N′-tetramethyl-1,11-undecanediamine and N,N,N′,N′-tetramethyl-1,12-dodecanediamine. In the Examples, crystallization is conducted by heating the reaction mixture to 120 to 200° C. for 4 to 48 hours.

U.S. Pat. No. 7,247,287 discloses the synthesis of silicoaluminophosphate molecular sieves having the CHA framework type employing a directing agent having the formula: R¹R²N—R³ wherein R¹ and R² are independently selected from the group consisting of alkyl groups having from 1 to 3 carbon atoms and hydroxyalkyl groups having from 1 to 3 carbon atoms and R³ is selected from the group consisting of 4- to 8-membered cycloalkyl groups, optionally substituted by 1 to 3 alkyl groups having from 1 to 3 carbon atoms; and 4- to 8-membered heterocyclic groups having from 1 to 3 heteroatoms, said heterocyclic groups being optionally substituted by 1 to 3 alkyl groups having from 1 to 3 carbon atoms and the heteroatoms in said heterocyclic groups being selected from the group consisting of O, N, and S. Preferably, the directing agent is selected from N,N-dimethylcyclohexylamine, N,N-dimethyl-methylcyclohexylamine, N,N-dimethyl-cyclopentylamine, N,N-dimethyl-methylcyclopentylamine, N,N-dimethylcycloheptyl-amine, N,N-dimethyl-methyl-cycloheptylamine, and most preferably is N,N-dimethyl-cyclohexylamine. The synthesis can be effected with or without the presence of fluoride ions and, in the Examples, crystallization is conducted by heating the reaction mixture to 180° C. for 3 to 7 days.

According to the present invention, it has unexpectedly been found that the order of addition and relative homogenization of the synthesis mixture components, as well as whether certain synthesis mixture components are inorganic or organic, in silicoaluminophosphate molecular sieve formulations can enhance certain desirable properties, such as reducing the crystal size of the product, while still maintaining an acceptable product yield. Interestingly, the use of organic sources of silicon, and optionally also phosphorus, as opposed to inorganic sources, can facilitate a more intimate/reactive combination of synthesis mixture components and appears to be a robust way to make the synthesis mixture, preferably resulting in more desirable molecular sieve products.

SUMMARY OF THE INVENTION

In one aspect, the invention relates to a method of preparing a silicoaluminophosphate molecular sieve having a desired crystal size, the method comprising: (a) combining a source of phosphorus and a source of aluminum, optionally with a liquid mixture medium, to form a primary mixture; (b) aging the primary mixture for an aging time and under aging conditions sufficient to allow homogenization of the primary mixture, physico-chemical interaction between the source of phosphorus and the source of aluminum, or both; (c) adding a source of silicon, at least one organic template, and optionally additional liquid mixture medium, to the aged primary mixture to form a synthesis mixture; and (d) inducing crystallization of a silicoaluminophosphate molecular sieve, which exhibits 90% or greater CHA framework type character, from said synthesis mixture at a crystallization temperature, wherein said source of silicon comprises an organosilicate and said source of phosphorus optionally comprises an organophosphate, and wherein the crystallized silicoaluminophosphate molecular sieve has a crystal size distribution such that its average crystal size is not greater than 5 μm.

In another aspect, the invention relates to a method of converting hydrocarbons into olefins comprising: (a) preparing a silicoaluminophosphate molecular sieve according to the method of the previous aspect of the invention; (b) formulating said silicoaluminophosphate molecular sieve, along with a binder and optionally a matrix material, into a silicoaluminophosphate molecular sieve catalyst composition comprising from at least 10% to about 50% molecular sieve; and (c) contacting said catalyst composition with a hydrocarbon feed under conditions sufficient to convert said hydrocarbon feed into a product comprising predominantly one or more olefins.

In another aspect, the invention relates to a method of forming an olefin-based polymer product comprising: (a) preparing a silicoaluminophosphate molecular sieve according to the method of the first aspect of the invention; (b) formulating said silicoaluminophosphate molecular sieve, along with a binder and optionally a matrix material, into a silicoaluminophosphate molecular sieve catalyst composition comprising from at least 10% to about 50% molecular sieve; (c) contacting said catalyst composition with a hydrocarbon feed under conditions sufficient to convert said hydrocarbon feed into a product comprising predominantly one or more olefins; (d) polymerizing at least one of the one or more olefins, optionally with one or more other comonomers and optionally in the presence of a polymerization catalyst, under conditions sufficient to form an olefin-based (co)polymer.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows an X-ray diffraction (XRD) analysis of a molecular sieve made according to Comparative Example A1.

FIG. 2 shows an SEM micrograph of a molecular sieve made according to Comparative Example A1.

FIG. 3 shows an XRD analysis of a molecular sieve made according to Comparative Example A2.

FIG. 4 shows an SEM micrograph of a molecular sieve made according to Comparative Example A2.

FIG. 5 shows an XRD analysis of a molecular sieve made according to Example 1.

FIG. 6 shows an SEM micrograph of a molecular sieve made according to Example 1.

FIG. 7 shows an XRD analysis of a molecular sieve made according to Example 2.

FIG. 8 shows an SEM micrograph of a molecular sieve made according to Example 2.

FIG. 9 shows an SEM micrograph of a molecular sieve made according to Example 3.

FIG. 10 shows an SEM micrograph of a molecular sieve made according to Example 4.

FIG. 11 shows an SEM micrograph of a molecular sieve made according to Comparative Example B 1.

FIG. 12 shows an SEM micrograph of a molecular sieve made according to Example 5.

FIG. 13 shows an SEM micrograph of a molecular sieve made according to Example 6.

FIG. 14 shows an SEM micrograph of a molecular sieve made according to Example 14.

FIG. 15 shows a graph of the yield of products made according to the invention with different silica sources and having various Si/Al₂ ratios in the synthesis mixture.

DETAILED DESCRIPTION OF THE EMBODIMENTS

Described herein is a method of synthesizing a crystalline aluminophosphate or silicoaluminophosphate containing a molecular sieve having 90% or greater CHA framework-type character and to the use of the resultant molecular sieve as a catalyst in organic conversion reactions, especially the conversion of oxygenates to light olefins.

In particular, it has been found that, by employing a particular order of addition of components (i.e., phosphorus and aluminum sources being combined first) and by incorporating certain organic sources (e.g., organosilicate and optionally also organophosphate) in the molecular sieve synthesis, it is possible to produce a 90% or greater CHA framework-type containing molecular sieve having a desirably reduced crystal size, e.g., 5 microns or less, instead of over 10 microns.

In a preferred embodiment, the order of addition of the components in the mixture (i.e., in step (a)) can be important and can advantageously be tailored, e.g., to provide better homogeneity. For instance, step (a) can preferably comprise: (i) combining the source of phosphorus and the source of aluminum, optionally with a liquid mixture medium, to form a primary mixture; (ii) aging the primary mixture for an aging time and under aging conditions (e.g., at an aging temperature), preferably sufficient to allow homogenization of the primary mixture, physico-chemical interaction between the source of phosphorus and the source of aluminum, or both; and (iii) adding the source of silicon, the at least one organic template, and optionally additional liquid mixture medium, to the aged primary mixture to form the synthesis mixture. In certain cases of this embodiment, within step (iii), said source of silicon is combined with said primary mixture prior to adding said at least one organic template (structure directing agent, or SDA). Advantageously, said primary mixture and said source of silicon can be combined to form a secondary mixture for a time and under conditions (e.g., temperature), preferably sufficient to allow homogenization of the secondary mixture, physico-chemical interaction between said source of silicon and said primary mixture, or both, after which said at least one organic template is combined therewith.

When a component is added to a mixture to allow homogenization and/or physico-chemical interaction, the aging time and temperature are two of the primary conditions. Although a variety of conditions can exist to allow sufficient contact for homogenization and/or interaction, in one embodiment, when the aging temperature is somewhere between 0° C. and 50° C., the aging time can advantageously be at least 5 minutes, for example at least 10 minutes, at least 15 minutes, at least 20 minutes, at least 25 minutes, at least 30 minutes, at least 45 minutes, at least 1 hour, or at least 2 hours. Again, when the aging temperature is somewhere between 0° C. and 50° C., the aging time does not really have a maximum, but can be up to 350 hours, for example up to 300 hours, up to 250 hours, up to 200 hours, up to 168 hours, up to 96 hours, up to 48 hours, up to 24 hours, up to 16 hours, up to 12 hours, up to 8 hours, up to 6 hours, or up to 4 hours, depending on practical concerns relating to synthesis timing, cost efficiency, manufacture schedules, or the like.

In the present method, a reaction mixture is prepared comprising a source of aluminum, a source of phosphorous, at least one organic directing agent, and, optionally, a source of silicon. Any organic directing agent capable of directing the synthesis of CHA framework type molecular sieves can be employed, but generally the directing agent is a compound having the formula (I): R¹R²N—R³   (I) wherein R¹ and R² are independently selected from the group consisting of alkyl groups having from 1 to 3 carbon atoms and hydroxyalkyl groups having from 1 to 3 carbon atoms and R³ is selected from the group consisting of 4- to 8-membered cycloalkyl groups, optionally substituted by 1 to 3 alkyl groups having from 1 to 3 carbon atoms; and 4- to 8-membered heterocyclic groups having from 1 to 3 heteroatoms, said heterocyclic groups being optionally substituted by 1 to 3 alkyl groups having from 1 to 3 carbon atoms and the heteroatoms in said heterocyclic groups being selected from the group consisting of O, N, and S.

More particularly, the organic directing agent is a compound having the formula (II): (CH₃)₂N—R³   (II) wherein R³ is a 4- to 8-membered cycloalkyl group, especially a cyclohexyl group, optionally substituted by 1 to 3 methyl groups. Particular examples of suitable organic directing agents include, but are not limited to, at least one of N,N-dimethyl-cyclohexylamine, N,N-dimethyl-methylcyclohexylamine, N,N-dimethyl-cyclopentylamine, N,N-dimethyl-methylcyclopentylamine, N,N-dimethyl-cycloheptylamine, and N,N-dimethyl-methylcycloheptylamine, especially N,N-dimethyl-cyclohexylamine

The sources of aluminum, phosphorus, and silicon suitable for use in the present synthesis method are typically those known in the art or as described in the literature for the production of aluminophosphates and silicoaluminophosphates. For example, the aluminum source may be an aluminum oxide (alumina), optionally hydrated, an aluminum salt, especially a phosphate, an aluminate, or a mixture thereof Other sources may include alumina sols or organic alumina sources, e.g., aluminum alkoxides such as aluminum isopropoxide. A preferred source is a hydrated alumina, most preferably pseudoboehmite, which contains about 75% Al₂O₃ and 25% H₂O by weight. Typically, the source of phosphorus is a phosphoric acid, especially orthophosphoric acid, although other phosphorus sources, for example, organophosphates (e.g., trialkylphosphates such as triethylphosphate) and aluminophosphates may be used. When organophosphates and/or aluminophosphates are used, typically they are present collectively in a minor amount (i.e., less than 50% by weight of the phosphorus source) in combination with a majority (i.e., at least 50% by weight of the phosphorus source) of an inorganic phosphorus source (such as phosphoric acid). Suitable sources of silicon include silica, for example colloidal silica and fumed silica, as well as organic silicon source, e.g., a tetraalkyl orthosilicate, preferably such as tetraethylorthosilicate (TEOS), tetramethylorthosilicate (TMOS), or the like, or a combination thereof.

Although, in most embodiments, the sources of silicon, phosphorus, and aluminum are the only components that form the framework of a calcined silicoaluminophosphate molecular sieve according to the invention, it is possible for some small portion (e.g., typically no more than about 10 wt %, preferably no more than about 5 wt %) of the silicon source can be substituted with a source of one or more of magnesium, zinc, iron, cobalt, nickel, manganese, and chromium.

In some embodiments, the reaction mixture can have a molar composition within the following ranges:

-   -   P₂O₅:Al₂O₃ from about 0.75 to about 1.25,     -   SiO₂:Al₂O₃ from about 0.01 to about 0.32,     -   H₂O:Al₂O₃ from about 25 to about 50, and     -   SDA:Al₂O₃ from about 1 to about 3,         where SDA designates the structure directing agent (template),         and wherein the molar ratios for the aluminum, phosphorus, and         silicon sources are calculated based on the oxide forms,         regardless of the form of the source added to the reaction         mixture (e.g., whether the phosphorus source is added to the         reaction mixture as phosphoric acid, H₃PO₄, or as         triethylphosphate, the molar ratio is normalized to P₂O₅ molar         equivalents).

Although the reaction mixture may also contain a source of fluoride ions, it is found that the present synthesis will proceed in the absence of fluoride ions, and hence it is generally preferred to employ a reaction mixture which is substantially free of fluoride ions.

Typically, the reaction mixture also contains seeds to facilitate the crystallization process. The amount of seeds employed can vary widely, but generally the reaction mixture comprises from about 0.01 ppm by weight to about 10,000 ppm by weight, such as from about 100 ppm by weight to about 5,000 by weight, of said seeds. Generally, the seeds can be homostructural with the desired product, that is are of a CHA framework type material, although heterostructural seeds of, for example, an AEI, LEV, ERI, AFX, or OFF framework-type molecular sieve, or a combination or intergrowth thereof, may be used. The seeds may be added to the reaction mixture as a suspension in a liquid medium, such as water; in some cases, particularly where the seeds are of relatively small size, the suspension can be colloidal. The production of colloidal seed suspensions and their use in the synthesis of molecular sieves are disclosed in, for example, International Publication Nos. WO 00/06493 and WO 00/06494, both published on Feb. 10, 2000 and both of which are incorporated herein by reference.

Crystallization of the reaction mixture is carried out at either static or stirred conditions in a suitable reactor vessel, such as for example, polypropylene jars or Teflon-lined or stainless steel autoclaves. In one embodiment, the crystallization regime can involve heating the reaction mixture relatively quickly, at a rate of more than 10° C./hour, conveniently at least 15° C./hour or at least 20° C./hour, for example from about 15° C./hour to about 150° C./hour or from about 20° C./hour to about 100° C./hour, to the desired crystallization temperature, typically between about 50° C. and about 250° C., for example from about 150° C. to about 225° C. or from about 150° C. to about 200° C., such as from about 160° C. to about 195° C. In some embodiments, however, the desired crystallization temperature is additionally at least 165° C., for example at least 170° C., and can optionally also be not more than 190° C., for example not more than 185° C. or not more than 180° C. In any of these embodiments, when the desired crystallization temperature is reached, the crystallization can be terminated immediately or from about 5 minutes to about 350 hours, and the reaction mixture can be allowed to cool; additionally or alternately, the crystallization can run for at least about 12 hours, preferably at least about 16 hours, for example at least 24 hours, at least 36 hours, at least 48 hours, at least 60 hours, at least 72 hours, at least 84 hours, at least 96 hours, at least 120 hours, or at least 144 hours before cooling. Additionally in this embodiment, on cooling, the crystalline product can be recovered by standard means, such as by centrifugation or filtration, then washed and dried.

In an alternate embodiment, the crystallization regime can involve heating the reaction mixture slowly, at a rate of less than 8° C./hour, conveniently at least 1° C./hour, such as from about 2° C./hour to about 6° C./hour, to the desired crystallization temperature, typically between about 50° C. and about 250° C., for example from about 150° C. to about 225° C. or from about 150° C. to about 200° C., such as from about 160° C. to about 195° C. In some embodiments, however, the desired crystallization temperature is additionally at least 165° C., for example at least 170° C., and can optionally also be not more than 190° C., for example not more than 185° C. or not more than 180° C. In any of these embodiments, when the desired crystallization temperature is reached, the crystallization can be terminated immediately or at least within less than 10 hours, such as less than 5 hours, and the reaction mixture can be allowed to cool. Additionally in this embodiment, on cooling, the crystalline product can be recovered by standard means, such as by centrifugation or filtration, then washed and dried.

Optionally, the step of inducing crystallization can be done while stirring.

In one embodiment, the crystallized silicoaluminophosphate molecular sieve has a crystal size distribution such that its average crystal size is no more than 5 μm, preferably no more than 3.0 μm, for example no more than 2.0 μm, no more than 1.5 μm, no more than 1.2 μm, no more than 1.1 μm, no more than 1.0 μm, or no more than 0.9 μm.

As used herein, the term “average crystal size,” in reference to a crystal size distribution, should be understood to refer to a measurement on a representative sample or an average of multiple samples that together form a representative sample. Average crystal size can be measured by SEM, in which case the crystal size of at least 30 crystals must be measured in order to obtain an average crystal size, and/or average crystal size can be measured by a laser light scattering particle size analyzer instrument, in which case the measured d₅₀ of the sample(s) can represent the average crystal size. It should also be understood that, while many of the crystals dealt with herein are relatively uniform (for instance, very close to cubic, thus having little difference between diameter measured along length, height, or width, e.g., when viewed in an SEM), the “average crystal size,” when measured visually by SEM, represents the longest distance along one of the three-dimensional orthogonal axes (e.g., longest of length, width/diameter, and height, but not diagonal, in a cube, rectangle, parallelogram, ellipse, cylinder, frusto-cone, platelet, spheroid, or rhombus, or the like). However, the d₅₀, when measured by light scattering in a particle size analyzer, is reported as a spherical equivalent diameter, regardless of the shape and/or relative uniformity of shape of the crystals in each sample. In certain circumstances, the d₅₀ values measured by the particle size analyzer may not correspond, even roughly, to the average crystal size measured visually by a representative SEM micrograph. Often in these cases, the discrepancy relates to an agglomeration of relatively small crystals that the particle size analyzer interprets as a single particle. In such circumstances, where the d₅₀ values from the particle size analyzer and the average crystal size from a representative SEM are significantly different, the representative SEM micrograph should be the more accurate measure of “average crystal size.”

Preferably, the Si/Al₂ ratio added to the synthesis mixture can be as close as possible to the Si/Al₂ ratio of the crystallized silicoaluminophosphate molecular sieve (e.g., difference between the Si/Al₂ ratio in the synthesis mixture and in the crystallized silicoaluminophosphate molecular sieve can be no more than 0.10, preferably no more than 0.08, for example no more than 0.07) and/or the synthesis mixture and the crystallized silicoaluminophosphate molecular sieve can both exhibit a relatively low Si/Al₂ ratio (e.g., both can be less than 0.33, preferably less than 0.30, for example no more than 0.25, no more than 0.20, no more than 0.15, or no more than 0.10).

In a preferred embodiment, one or more of the following are satisfied: the source of aluminum comprises alumina; the source of phosphorus comprises phosphoric acid and an organophosphate comprising a trialkylphosphate; the source of silicon can include an organosilicate comprising a tetraalkylorthosilicate; and the at least one organic template comprises N,N-dimethylcyclohexylamine.

The product of the crystallization is an aluminophosphate or silicoaluminophosphate containing a CHA framework-type molecular sieve having an X-ray diffraction pattern including at least the d-spacings shown in Table 1 below:

TABLE 1 Relative Intensities d(A) I/Io (%) 9.26 100 6.30 20 5.64 15 5.51 57 4.96 25 4.92 27 4.29 76 4.18 21 3.55 32 3.50 20 3.42 10 2.91 22 2.88 26 2.87 19

Although the crystallization product is normally a single phase CHA framework-type molecular sieve, in some cases the product may contain an intergrowth of a CHA framework-type molecular sieve with, for example an AEI framework-type molecular sieve or small amounts of other crystalline phases, such as APC and/or AFI framework-type molecular sieves. In one embodiment, it is preferable for the crystallization product to have as high an amount of CHA framework type as possible, e.g., at least 95% CHA framework-type character, or even about 100% CHA framework-type character (or as close as possible to single phase CHA framework-type character as can currently be measured). Without being bound by theory, it is believed that silicoaluminophosphate molecular sieves having increased CHA framework-type character (and/or increased uniformity of distribution of silicon within the molecular sieve framework structure, i.e., decreased amounts of silicon islanding) can advantageously exhibit better performance (e.g., increased POS, which means prime olefin selectivity, or selectivity to the combination of ethylene and propylene, and optionally also POR, which means prime olefin, or ethylene-to-propylene, ratio) in oxygenates-to-olefins conversion reactions, particularly in methanol-to-olefins conversion reactions.

As a result of the crystallization process, the recovered crystalline product contains within its pores at least a portion of the organic directing agent used in the synthesis. In a preferred embodiment, activation is performed in such a manner that the organic directing agent is removed from the molecular sieve, leaving active catalytic sites within the microporous channels of the molecular sieve open for contact with a feedstock. The activation process is typically accomplished by calcining, or essentially heating the molecular sieve comprising the template at a temperature of from about 200° C. to about 800° C. in the presence of an oxygen-containing gas. In some cases, it may be desirable to heat the molecular sieve in an environment having a low or zero oxygen concentration. This type of process can be used for partial or complete removal of the organic directing agent from the intracrystalline pore system.

Once the crystalline product has been activated, it can be formulated into a catalyst composition by combination with other materials, such as binders and/or matrix materials, which provide additional hardness or catalytic activity to the finished catalyst.

Materials which can be blended with the present molecular sieve material include a large variety of inert and catalytically active materials. These materials include compositions such as kaolin and other clays, various forms of rare earth metals, other non-zeolite catalyst components, zeolite catalyst components, alumina or alumina sol, titania, zirconia, quartz, silica or silica sol, and mixtures thereof. These components are also effective in reducing overall catalyst cost, acting as a thermal sink to assist in heat shielding the catalyst during regeneration, densifying the catalyst and increasing catalyst strength. When blended with such components, the amount of present CHA-containing crystalline material contained in the final catalyst product ranges from 10 to 90 weight percent of the total catalyst, preferably 20 to 80 weight percent of the total catalyst.

The CHA framework type crystalline material produced by the present process can be used to dry gases and liquids; for selective molecular separation based on size and polar properties; as an ion-exchanger; as a chemical carrier; in gas chromatography; and as a catalyst in organic conversion reactions. Examples of suitable catalytic uses of the CHA framework type crystalline material described herein include (a) hydrocracking of heavy petroleum residual feedstocks, cyclic stocks and other hydrocrackate charge stocks, normally in the presence of a hydrogenation component selected from Groups 6 and 8-10 of the Periodic Table of Elements; (b) dewaxing, including isomerization dewaxing, to selectively remove straight chain paraffins from hydrocarbon feedstocks typically boiling above 177° C., including raffinates and lubricating oil basestocks; (c) catalytic cracking of hydrocarbon feedstocks, such as naphthas, gas oils, and residual oils, normally in the presence of a large pore cracking catalyst, such as zeolite Y; (d) oligomerization of straight and branched chain olefins having from 2-21, preferably 2-5, carbon atoms, to produce medium to heavy olefins which are useful for both fuels, e.g., gasoline or a gasoline blending stock, and chemicals; (e) isomerization of olefins, particularly olefins having 4-6 carbon atoms, and especially normal butene to produce iso-olefins; (f) upgrading of lower alkanes, such as methane, to higher hydrocarbons, such as ethylene and benzene; (g) disproportionation of alkylaromatic hydrocarbons, such as toluene, to produce dialkylaromatic hydrocarbons, such as xylenes; (h) alkylation of aromatic hydrocarbons, such as benzene, with olefins, such as ethylene and propylene, to produce alkylated aromatics, such as ethylbenzene and cumene; (i) isomerization of dialkylaromatic hydrocarbons, such as xylenes; (j) catalytic reduction of nitrogen oxides; and (k) synthesis of monoalkylamines and dialkylamines.

In particular, the CHA framework type crystalline material produced by the present process is useful as a catalyst in the conversion of oxygenates to one or more olefins, particularly ethylene and propylene. As used herein, the term “oxygenates” is defined to include, but is not necessarily limited to, aliphatic alcohols, ethers, carbonyl compounds (aldehydes, ketones, carboxylic acids, carbonates, and the like), and also compounds containing hetero-atoms, such as, halides, mercaptans, sulfides, amines, and mixtures thereof The aliphatic moiety will normally contain from 1-10 carbon atoms, such as from 1-4 carbon atoms.

Representative oxygenates include lower straight chain or branched aliphatic alcohols, their unsaturated counterparts, and their nitrogen, halogen, and sulfur analogues. Examples of suitable oxygenate compounds can include, but are not necessarily limited to: methanol; ethanol; n-propanol; isopropanol; C₄ to C₁₀ alcohols; methyl ethyl ether; dimethyl ether; diethyl ether; di-isopropyl ether; methyl mercaptan; methyl sulfide; methyl amine; ethyl mercaptan; di-ethyl sulfide; di-ethyl amine; ethyl chloride; formaldehyde; di-methyl carbonate; di-methyl ketone; acetic acid; n-alkyl amines; n-alkyl halides; n-alkyl sulfides having n-alkyl groups comprising from 3-10 carbon atoms; and the like; and mixtures thereof Particularly suitable oxygenate compounds are methanol, dimethyl ether, and mixtures thereof, and most preferably comprise methanol. As used herein, the term “oxygenate” designates only the organic material used as the feed. The total charge of feed to the reaction zone may contain additional compounds, such as diluents.

In one embodiment of the oxygenate conversion process, a feedstock comprising an organic oxygenate, optionally with one or more diluents, is contacted in the vapor phase in a reaction zone with a catalyst comprising the present molecular sieve at effective process conditions so as to produce the desired olefins. Alternatively, the process may be carried out in a liquid or a mixed vapor/liquid phase. When the process is carried out in the liquid phase or a mixed vapor/liquid phase, different conversion rates and selectivities of feedstock-to-product may result depending upon the catalyst and the reaction conditions.

When present, the diluent(s) is(are) generally non-reactive to the feedstock or molecular sieve catalyst composition and is typically used to reduce the concentration of the oxygenate in the feedstock. Non-limiting examples of suitable diluents include helium, argon, nitrogen, carbon monoxide, carbon dioxide, water, essentially non-reactive paraffins (especially alkanes such as methane, ethane, and propane), essentially non-reactive aromatic compounds, and mixtures thereof The most preferred diluents include water and nitrogen, with water being particularly preferred. Diluent(s) may comprise from about 1 mol % to about 99 mol % of the total feed mixture.

The temperature employed in the oxygenate conversion process may vary over a wide range, such as from about 200° C. to about 1000° C., for example from about 250° C. to about 800° C., including from about 250° C. to about 750° C., conveniently from about 300° C. to about 650° C., typically from about 350° C. to about 600° C. and particularly from about 400° C. to about 600° C.

Light olefin products will form, although not necessarily in optimum amounts, at a wide range of pressures, including but not limited to autogenous pressures and pressures in the range from about 0.1 kPa to about 10 MPa. Conveniently, the pressure can be in the range from about 7 kPa to about 5 MPa, such as from about 50 kPa to about 1 MPa. The foregoing pressures are exclusive of diluents, if any are present, and refer to the partial pressure of the feedstock as it relates to oxygenate compounds and/or mixtures thereof Lower and upper extremes of pressure may adversely affect selectivity, conversion, coking rate, and/or reaction rate; however, light olefins such as ethylene and/or propylene still may form.

In a preferred embodiment, the method of converting hydrocarbons into olefins according to the invention comprises: (a) preparing a silicoaluminophosphate molecular sieve according to the methods disclosed hereinabove; (b) formulating said silicoaluminophosphate molecular sieve, along with a binder and optionally a matrix material, into a silicoaluminophosphate molecular sieve catalyst composition, typically comprising from at least 10% to about 50% molecular sieve; and (c) contacting said catalyst composition with a hydrocarbon feed under conditions sufficient to convert said hydrocarbon feed into a product comprising predominantly one or more olefins, preferably to attain a prime olefin selectivity of at least 70 wt % (as measured at about 500° C.). Preferably, the hydrocarbon feed is an oxygenate-containing feed comprising methanol, dimethylether, or a combination thereof, and the one or more olefins typically comprises ethylene, propylene, or a combination thereof.

A wide range of weight hourly space velocities (WHSV) for the feedstock will function in the oxygenate conversion process. WHSV is defined as weight of feed (excluding diluents) per hour per weight of a total reaction volume of molecular sieve catalyst (excluding inert and/or fillers). The WHSV generally should be in the range from about 0.01 hr⁻¹ to about 500 hr⁻¹, such from about 0.5 hr⁻¹ to about 300 hr⁻¹, for example from about 0.1 hr⁻¹ to about 200 hr⁻¹.

A practical embodiment of a reactor system for the oxygenate conversion process is a circulating fluid bed reactor with continuous regeneration. Fixed beds are generally not preferred for the process, because oxygenate-to-olefin conversion is a highly exothermic process that requires several stages with intercoolers or other cooling devices. The reaction also results in a high pressure drop, due to the production of low pressure, low density gas.

Because the catalyst typically needs to be regenerated frequently, the reactor should preferably allow easy removal of at least a portion of the catalyst to a regenerator, where the catalyst can be subjected to a regeneration medium, such as a gas comprising oxygen, for example air, to burn off coke from the catalyst, which should restore at least some of the catalyst activity. The conditions of temperature, oxygen partial pressure, and residence time in the regenerator can typically be selected to achieve a coke content on regenerated catalyst of less than about 1 wt %, for example less than about 0.5 wt %. At least a portion of the regenerated catalyst should be returned to the reactor.

In a preferred embodiment, the method of forming an olefin-based polymer product comprises: (a) preparing a silicoaluminophosphate molecular sieve according to the methods described hereinabove; (b) formulating said silicoaluminophosphate molecular sieve, along with a binder and optionally a matrix material, into a silicoaluminophosphate molecular sieve catalyst composition comprising from at least 10% to about 50% molecular sieve; (c) contacting said catalyst composition with a hydrocarbon feed under conditions sufficient to convert said hydrocarbon feed into a product comprising predominantly one or more olefins, preferably to attain a prime olefin selectivity of at least 70 wt % (as measured at about 500° C.); and (d) polymerizing at least one of the one or more olefins, optionally with one or more other comonomers and optionally (but preferably) in the presence of a polymerization catalyst, under conditions sufficient to form an olefin-based (co)polymer. Preferably, in this preferred embodiment, the hydrocarbon feed is an oxygenate-containing feed comprising methanol, dimethylether, or a combination thereof, the one or more olefins typically comprises ethylene, propylene, or a combination thereof, and the olefin-based (co)polymer is an ethylene-containing (co)polymer, a propylene-containing (co)polymer, or a copolymer, mixture, or blend thereof.

Additionally or alternately, the invention can be described by the following embodiments.

Embodiment 1. A method of preparing a silicoaluminophosphate molecular sieve having a desired crystal size, the method comprising: (a) combining a source of phosphorus and a source of aluminum, optionally with a liquid mixture medium, to form a primary mixture; (b) aging the primary mixture for an aging time and under aging conditions sufficient to allow homogenization of the primary mixture, physico-chemical interaction between the source of phosphorus and the source of aluminum, or both; (c) adding a source of silicon, at least one organic template, and optionally additional liquid mixture medium, to the aged primary mixture to form a synthesis mixture; and (d) inducing crystallization of a silicoaluminophosphate molecular sieve, which exhibits 90% or greater CHA framework type character, from said synthesis mixture at a crystallization temperature, wherein said source of silicon comprises an organosilicate and said source of phosphorus optionally comprises an organophosphate, and wherein the crystallized silicoaluminophosphate molecular sieve has a crystal size distribution such that the average crystal size is not greater than 5 μm.

Embodiment 2. The method of embodiment 1, wherein the at least one organic template contains (i) a 4- to 8-membered cycloalkyl group, optionally substituted by 1-3 alkyl groups having from 1-3 carbon atoms, or (ii) a 4- to 8-membered heterocyclic group having from 1-3 heteroatoms, said heterocyclic group being optionally substituted by 1-3 alkyl groups having from 1-3 carbon atoms, and said heteroatoms in said heterocyclic groups being selected from the group consisting of O, N, and S.

Embodiment 3. The method of embodiment 1 or embodiment 2, wherein the at least one organic template comprises N,N-dimethylcyclohexylamine

Embodiment 4. The method of any of the previous embodiments, wherein the crystallized silicoaluminophosphate molecular sieve exhibits a Si/Al₂ ratio not more than 0.10 greater than the Si/Al₂ ratio of the synthesis mixture.

Embodiment 5. The method of any of the previous embodiments, wherein said crystallization temperature is between 150° C. and 200° C.

Embodiment 6. The method of any of the previous embodiments, wherein the crystallized silicoaluminophosphate molecular sieve has a crystal size distribution such that the average crystal size is less than 2.0 μm.

Embodiment 7. The method of any of the previous embodiments, wherein the crystallized silicoaluminophosphate molecular sieve has a crystal size distribution such that the average crystal size is less than 1.2 μm.

Embodiment 8. The method of any of the previous embodiments, wherein the inducing step is done while stirring.

Embodiment 9. The method of any of the previous embodiments, wherein, within step (c), said source of silicon is combined with said primary mixture prior to adding said at least one organic template.

Embodiment 10. The method of embodiment 9, wherein said primary mixture and said source of silicon are combined to form a secondary mixture for a time and under conditions sufficient to allow homogenization of the secondary mixture, physico-chemical interaction between said source of silicon and said primary mixture, or both, after which said at least one organic template is combined therewith.

Embodiment 11. The method of any of the previous embodiments, wherein the synthesis mixture and the crystallized silicoaluminophosphate molecular sieve both exhibit a Si/Al₂ ratio less than 0.33.

Embodiment 12. The method of any of embodiments 1-2 and 4-11, wherein one or more of the following are satisfied: the source of aluminum comprises alumina; the source of phosphorus comprises phosphoric acid and an organophosphate comprising a trialkylphosphate; the organosilicate comprises a tetraalkylorthosilicate; and the at least one organic template comprises N,N-dimethylcyclohexylamine

Embodiment 13. The method of any of the previous embodiments, wherein the organosilicate comprises tetramethylorthosilicate, tetraethylorthosilicate, or a combination thereof.

Embodiment 14. The method of any of the previous embodiments, wherein step (b) was accomplished using seeds having a framework type of CHA, AEI, AFX, LEV, an intergrowth thereof, or a combination thereof.

Embodiment 15. A method of converting hydrocarbons into olefins comprising: (a) preparing a silicoaluminophosphate molecular sieve according to the method of any of the previous embodiments; (b) formulating said silicoaluminophosphate molecular sieve, along with a binder and optionally a matrix material, into a silicoaluminophosphate molecular sieve catalyst composition comprising from at least 10% to about 50% molecular sieve; and (c) contacting said catalyst composition with a hydrocarbon feed under conditions sufficient to convert said hydrocarbon feed into a product comprising predominantly one or more olefins.

Embodiment 16. The method of embodiment 15, wherein the hydrocarbon feed is an oxygenate-containing feed comprising methanol, dimethylether, or a combination thereof, and wherein the one or more olefins comprises ethylene, propylene, or a combination thereof.

Embodiment 17. A method of forming an olefin-based polymer product comprising: (a) preparing a silicoaluminophosphate molecular sieve according to the method of any of embodiments 1-14; (b) formulating said silicoaluminophosphate molecular sieve, along with a binder and optionally a matrix material, into a silicoaluminophosphate molecular sieve catalyst composition comprising from at least 10% to about 50% molecular sieve; (c) contacting said catalyst composition with a hydrocarbon feed under conditions sufficient to convert said hydrocarbon feed into a product comprising predominantly one or more olefins; (d) polymerizing at least one of the one or more olefins, optionally with one or more other comonomers and optionally in the presence of a polymerization catalyst, under conditions sufficient to form an olefin-based (co)polymer.

Embodiment 18. The method of embodiment 17, wherein the hydrocarbon feed is an oxygenate-containing feed comprising methanol, dimethylether, or a combination thereof, wherein the one or more olefins comprises ethylene, propylene, or a combination thereof, and wherein the olefin-based (co)polymer is an ethylene-containing (co)polymer, a propylene-containing (co)polymer, or a copolymer, mixture, or blend thereof

The invention will now be more particularly described with reference to the following Examples and the accompanying drawings.

EXAMPLES

The analysis techniques described below were among those used in characterizing various samples from the Examples.

ICP-OES

Elemental analysis has been done using ICP-OES (Inductively Coupled Plasma-Optical Emission Spectrometry). Samples were dissolved in a mixture of acids and diluted in deionized water. The instrument (Simultaneous VISTA-MPX from Varian) was calibrated using commercial available standards (typically at least 3 standards and a blank). The power used was about 1.2 kW, plasma flow about 13.5 L/min, and nebulizer pressure about 200 kPa for all lines. Results are expressed in wt % or ppm by weight (wppm), and the values are recalculated to Si/Al₂ molar ratios.

XRD

Either of two X-ray diffractometers was used: a STOE Stadi-P Combi

Transmission XRD and a Scintag X2 Reflection XRD with optional sample rotation. Cu—K_(α) radiation was used. Typically, a step size of 0.2° 2Θ and a measurement time of about 1 hour were used.

SEM

A JEOL JSM-6340F Field-Emission-Gun scanning electron microscope (SEM) was used, operating at about 2 kV and about 12 μA. Prior to measurement, samples were dispersed in ethanol, subjected to ultrasonic treatment for about 5 to about 30 minutes, deposited on SEM sample holders, and dried at room temperature and pressure (about 20-25° C. and about 101 kPa). If an average particle size was determined based on the SEM micrographs, typically the measurement was performed on at least 30 crystals. In case of the near cubic crystals, the average was based on the sizes of one of the edges of each crystal.

PSA

Particle size analysis was performed using a Mastersizer APA2000 from Malvern Instruments Limited, equipped with a 4 mW laser beam, based on laser scattering by randomly moving particles in a liquid medium. The samples to be measured were dispersed in water under continuous ultrasonic treatment to ensure proper dispersion. The pump speed applied was 2000 RPM, and the stirrer speed was 800 RPM. The parameters used in the operation procedure were: Refractive Index=1.544, Absorption=0.1. The results were calculated using the “general purpose-enhanced sensitivity” model. The results were expressed as d₅₀, meaning that 50 vol % of the particles were smaller than the value. The average of at least 2 measurements, with a delay of at least about 10 seconds, was reported.

Comparative Example A1

A synthesis mixture having a molar composition of about 0.15 SiO₂:P₂O₅: Al₂O₃:1.5 DMCHA:40 H₂O, as well as 100 wt ppm (wppm) seeds, was prepared according to the following procedure. A solution of phosphoric acid was prepared by combining phosphoric acid [Acros, 85%] and water. To this solution was added the appropriate amount of Condea Pural SB [Sasol, 74.2 wt % Al₂O₃], and the slurry was stirred for about 10 minutes at about 10° C. To this mixture was added the appropriate amount of Ludox AS40 [ammonium stabilized silica sol containing 40 wt % SiO₂, from Grace NV] and the slurry was stirred for about another 10 minutes at about 10° C. Then the appropriate amount of dimethylcyclohexylamine [DMCHA, 99%, from Purum Fluka] was added. This mixture was stirred for about 10 minutes before the seeds (SAPO-34 seeds) were added. The final mixture was transferred to an autoclave which was stirred at approximately room temperature (about 20-25° C.) for about 2 hours, followed by heating, while stirring, to about 170° C. with a heat-up rate of about 40° C./hr. After about 72 hours this temperature, the autoclave was cooled to approximately room temperature, and the solids were washed with demineralized water and dried at about 120° C. The yield was determined by weighing the dried solids and dividing this weight by the weight of the initial synthesis mixture. The so-calculated yield was about 12.5 wt %. The phase purity of the sample was determined by X-ray diffraction to contain CHA framework, by virtue of exhibiting the peaks listed in Table 1 above, but also contained a significant amount of peaks indicating AFI framework. The XRD pattern is shown in FIG. 1. An SEM micrograph was recorded (FIG. 2), and the crystal size was approximated to be about 10 μm.

Comparative Example A2

A synthesis mixture having a molar composition of about 0.15 SiO₂:0.75 P₂O₅: Al₂O₃:1.5 DMCHA:40 H₂O, as well as 100 wt ppm seeds, was prepared according to the following procedure. A solution of phosphoric acid was prepared by combining phosphoric acid [Acros, 85%] and water. To this solution was added the appropriate amount of Condea Pural SB [Sasol, 74.2 wt % Al₂O₃], and the slurry was stirred for about 10 minutes at about 10° C. To this mixture was added the appropriate amount of Ludox AS40 [ammonium stabilized silica sol containing 40 wt % SiO₂, from Grace NV] and the slurry was stirred for about another 10 minutes at about 10° C. Then the appropriate amount of dimethylcyclohexylamine [DMCHA, 99%, from Purum Fluka] was added. This mixture was stirred for about 10 minutes before the seeds (SAPO-34 seeds) were added. The final mixture was transferred to an autoclave which was stirred at approximately room temperature for about 2 hours, followed by heating, while stirring, to about 170° C. with a heat-up rate of about 40° C./hr. After about 72 hours this temperature, the autoclave was cooled to approximately room temperature, and the solids were washed with demineralized water and dried at about 120° C. The yield was determined by weighing the dried solids and dividing this weight by the weight of the initial synthesis mixture. The so-calculated yield was about 14.9 wt %. The phase purity of the sample was determined by X-ray diffraction and was characterized substantially by the d-spacings shown in Table 1 above. The XRD pattern is shown in FIG. 3. An SEM micrograph was recorded (FIG. 4), and the crystal size was approximated to be about 10 μm or smaller.

Example 1

A synthesis mixture having a molar composition of about 0.15 SiO₂:P₂O₅: Al₂O₃:1.5 DMCHA:40 H₂O, as well as 100 wt ppm seeds, was prepared according to the following procedure. A solution of phosphoric acid was prepared by combining phosphoric acid [Acros, 85%] and water. About 25% of this phosphoric acid solution was removed and in its place a corresponding molar amount of triethylphosphate [TEP, 99.8+%, from Aldrich] was added. To this solution was added the appropriate amount of Condea Pural SB [Sasol, 74.2 wt % Al₂O₃], and the slurry was stirred for about 10 minutes at about 10° C. To this mixture was added the appropriate amount of Ludox AS40 [ammonium stabilized silica sol containing 40 wt % SiO₂, from Grace NV] and the slurry was stirred for about another 10 minutes at about 10° C. Then the appropriate amount of dimethylcyclohexylamine [DMCHA, 99%, from Purum Fluka] was added. This mixture was stirred for about 10 minutes before the seeds (SAPO-34 seeds) were added. The final mixture was transferred to an autoclave which was stirred at approximately room temperature for about 2 hours, followed by heating, while stirring, to about 170° C. with a heat-up rate of about 40° C./hr. After about 72 hours this temperature, the autoclave was cooled to approximately room temperature, and the solids were washed with demineralized water and dried at about 120° C. The yield was determined by weighing the dried solids and dividing this weight by the weight of the initial synthesis mixture. The so-calculated yield was about 15.5 wt %. The phase purity of the sample was determined by X-ray diffraction and was characterized substantially by the d-spacings shown in Table 1 above. The XRD pattern is shown in FIG. 5. An SEM micrograph was recorded (FIG. 6), and the crystal size was determined to be about 5 μm or smaller.

Example 2

A synthesis mixture having a molar composition of about 0.15 SiO₂:P₂O₅: Al₂O₃:1.5 DMCHA:35 H₂O, as well as 100 wt ppm seeds, was prepared according to the following procedure. A solution of phosphoric acid was prepared by combining phosphoric acid [Acros, 85%] and water. About 25 mol % of this phosphoric acid solution was removed. To this solution was added the appropriate amount of Condea Pural SB [Sasol, 74.2 wt % Al₂O₃], and the slurry was stirred for about 10 minutes at about 10° C. To this mixture was added the appropriate amount of Ludox AS40 [40 wt % SiO₂, from Grace NV] and the slurry was stirred for about another 10 minutes at about 10° C. Then the appropriate amount of dimethylcyclohexylamine [DMCHA, 99%, from Purum Fluka] was added. To this mixture was added triethylphosphate [TEP, 99.8+%, from Aldrich] in a molar amount corresponding to the removed phosphoric acid. This mixture was stirred for about 10 minutes before the seeds (SAPO-34 seeds) were added. The final mixture was transferred to an autoclave which was stirred at approximately room temperature for about 2 hours, followed by heating, while stirring, to about 170° C. with a heat-up rate of about 40° C./hr. After about 72 hours this temperature, the autoclave was cooled to approximately room temperature, and the solids were washed with demineralized water and dried at about 120° C. The yield was determined by weighing the dried solids and dividing this weight by the weight of the initial synthesis mixture. The so-calculated yield was about 13.8 wt %. The phase purity of the sample was determined by X-ray diffraction and was characterized substantially by the d-spacings shown in Table 1 above. The XRD pattern is shown in FIG. 7. An SEM micrograph was recorded (FIG. 8), and the crystal size was determined to be about 5 μm or smaller.

Example 3

A synthesis mixture having a molar composition of about 0.15 SiO₂:P₂O₅: Al₂O₃:1.5 DMCHA:40 H₂O, as well as 100 wt ppm seeds, was prepared according to the following procedure. A solution of phosphoric acid was prepared by combining phosphoric acid [Acros, 85%] and water. About 25 mol % of this phosphoric acid solution was removed. To this solution was added the appropriate amount of Condea Pural SB [Sasol, 74.2 wt % Al₂O₃], and the slurry was stirred for about 10 minutes at about 10° C. To this mixture was added the appropriate amount of tetraethylorthosilicate [TEOS, 98%, from Aldrich] and the slurry was stirred for about another 10 minutes at about 10° C. Then the appropriate amount of dimethylcyclohexylamine [DMCHA, 99%, from Purum Fluka] was added. To this mixture was added triethylphosphate [TEP, 99.8+%, from Aldrich] in a molar amount corresponding to the removed phosphoric acid. This mixture was stirred for about 10 minutes before the seeds (SAPO-34 seeds) were added. The final mixture was transferred to an autoclave which was stirred at approximately room temperature for about 2 hours, followed by heating, while stirring, to about 170° C. with a heat-up rate of about 40° C./hr.

After about 72 hours this temperature, the autoclave was cooled to approximately room temperature, and the solids were washed with demineralized water and dried at about 120° C. The phase purity of the sample was determined by X-ray diffraction and was characterized substantially by the d-spacings shown in Table 1 above. An SEM micrograph was recorded (FIG. 9), and the crystal size was determined to be smaller than about 1 μm.

Example 4

A synthesis mixture having a molar composition of about 0.15 SiO₂:P₂O₅: Al₂O₃:1.5 DMCHA:35 H₂O, as well as 100 wt ppm seeds, was prepared according to the following procedure. A solution of phosphoric acid was prepared by combining phosphoric acid [Acros, 85%] and water. About 25 mol % of this phosphoric acid solution was removed. To this solution was added the appropriate amount of Condea Pural SB [Sasol, 74.2 wt % Al₂O₃], and the slurry was stirred for about 10 minutes at about 10° C. To this mixture was added the appropriate amount of tetraethylorthosilicate [TEOS, 98%, from Aldrich] and the slurry was stirred for about another 10 minutes at about 10° C. Then the appropriate amount of dimethylcyclohexylamine [DMCHA, 99%, from Purum Fluka] was added. To this mixture was added triethylphosphate [TEP, 99.8+%, from Aldrich] in a molar amount corresponding to the removed phosphoric acid. This mixture was stirred for about 10 minutes before the seeds (SAPO-34 seeds) were added. The final mixture was transferred to an autoclave which was stirred at approximately room temperature for about 2 hours, followed by heating, while stirring, to about 170° C. with a heat-up rate of about 40° C./hr. After about 72 hours this temperature, the autoclave was cooled to approximately room temperature, and the solids were washed with demineralized water and dried at about 120° C. The phase purity of the sample was determined by X-ray diffraction and was characterized substantially by the d-spacings shown in Table 1 above. An SEM micrograph was recorded (FIG. 10), and the crystals appear to be relatively homogeneous in size and smaller than about 1 μm.

Comparative Example B1

A synthesis mixture having a molar composition of about 0.15 SiO₂:P₂O₅: Al₂O₃:2 DMCHA:40 H₂O, as well as 100 wt ppm seeds, was prepared according to the following procedure. A solution of phosphoric acid was prepared by combining phosphoric acid [Acros, 85%] and water. To this solution was added the appropriate amount of Condea Pural SB [Sasol, 75.6 wt % Al₂O₃], and the slurry was stirred for about 1 hour at about 10° C. To this mixture was added the appropriate amount of Ludox AS40 [ammonium stabilized silica sol containing 40 wt % SiO₂, from Grace NV]. Then the appropriate amount of dimethylcyclohexylamine [DMCHA, 99%, from Purum Fluka] was added. This mixture was stirred for about 10 minutes before the seeds (SAPO-34 seeds) were added. The final mixture was transferred to an autoclave which was heated, while stirring, to about 170° C. with a heat-up rate of about 20° C./hr. After about 24 hours this temperature, the autoclave was cooled to approximately room temperature, and the solids were washed with demineralized water and dried at about 120° C. The yield was determined by weighing the dried solids and dividing this weight by the weight of the initial synthesis mixture. The so-calculated yield was about 17.2 wt %. The phase purity of the sample was determined by X-ray diffraction and was characterized substantially by the d-spacings shown in Table 1 above. An SEM micrograph was recorded (FIG. 11), and the crystal size was determined, on average, to be approximately 2.5 μm.

Example 5

A synthesis mixture having a molar composition of about 0.15 SiO₂:P₂O₅: Al₂O₃:2 DMCHA:40 H₂O, as well as 100 wt ppm seeds, was prepared according to the following procedure. A solution of phosphoric acid was prepared by combining phosphoric acid [Acros, 85%] and water. To this solution was added the appropriate amount of Condea Pural SB [Sasol, 75.6 wt % Al₂O₃], and the slurry was stirred for about 1 hour at about 10° C. To this mixture was added the appropriate amount of tetraethylorthosilicate [TEOS, 98%, from Aldrich]. Then the appropriate amount of dimethylcyclohexylamine [DMCHA, 99%, from Purum Fluka] was added. This mixture was stirred for about 10 minutes before the seeds (SAPO-34 seeds) were added. The final mixture was transferred to an autoclave which was heated, while stirring, to about 170° C. with a heat-up rate of about 20° C./hr. After about 24 hours this temperature, the autoclave was cooled to approximately room temperature, and the solids were washed with demineralized water and dried at about 120° C. The yield was determined by weighing the dried solids and dividing this weight by the weight of the initial synthesis mixture. The so-calculated yield was about 10.5 wt %. The phase purity of the sample was determined by X-ray diffraction and was characterized substantially by the d-spacings shown in Table 1 above. An SEM micrograph was recorded (FIG. 12), and the crystal size was determined, on average, to be about 0.4 μm or smaller.

Example 6

A synthesis mixture having a molar composition of about 0.11 SiO₂:P₂O₅: Al₂O₃:2 DMCHA:40 H₂O, as well as 400 wt ppm seeds, was prepared according to the following procedure. A solution of phosphoric acid was prepared by combining phosphoric acid [Acros, 85%] and water. To this solution was added the appropriate amount of Condea Pural SB [Sasol, 75.6 wt % Al₂O₃], and the slurry was stirred for about 1 hour at about 10° C. To this mixture was added the appropriate amount of tetraethylorthosilicate [TEOS, 98%, from Aldrich]. This mixture was then aged at about 10° C. while stirring for about another one hour. Then the appropriate amount of dimethylcyclohexylamine [DMCHA, 99%, from Purum Fluka] was added. This mixture was stirred for about 10 minutes before the seeds (SAPO-34 seeds) were added. The final mixture was transferred to an autoclave which was heated, while stirring, to about 160° C. with a heat-up rate of about 40° C./hr. After about 144 hours this temperature, the autoclave was cooled to approximately room temperature, and the solids were washed with demineralized water and dried at about 120° C. The yield was determined by weighing the dried solids and dividing this weight by the weight of the initial synthesis mixture. The so-calculated yield was about 6.9 wt%. The phase purity of the sample was determined by X-ray diffraction and was characterized substantially by the d-spacings shown in Table 1 above. An SEM micrograph was recorded (FIG. 13), and the crystal size was determined, on average, to be about 0.3 μm or smaller.

Examples 7-13

A series of samples was made according to the same procedure as Example 6, but only changing the Si/Al₂ ratio of the synthesis mixture. All products resulted in materials characterized substantially by the d-spacings shown in Table 1 above, with an average crystal size of about 0.4 μm. The yield results are summarized in Table 2.

TABLE 2 Yield of products made using TEOS according to Examples 6-13 with a heat-up rate of about 40° C./hr and various Si/Al₂ ratios in the mixture. Example Si/Al₂ Yield % 6 0.11 6.9 7 0.12 8.0 8 0.13 8.2 9 0.14 9.2 10 0.15 9.8 11 0.16 10.3 12 0.17 10.6 13 0.18 10.1

Example 14

A synthesis mixture having a molar composition of about 0.11 SiO₂:P₂O₅: Al₂O₃:2 DMCHA:40 H₂O, as well as 400 wt ppm seeds, was prepared according to the following procedure. A solution of phosphoric acid was prepared by combining phosphoric acid [Acros, 85%] and water. To this solution was added the appropriate amount of Condea Pural SB [Sasol, 75.6 wt % Al₂O₃], and the slurry was stirred for about 1 hour at about 10° C. To this mixture was added the appropriate amount of tetraethylorthosilicate [TMOS, 99%, from Fluka]. This mixture was then aged at about 10° C. while stirring for about another one hour. Then the appropriate amount of dimethylcyclohexylamine [DMCHA, 99%, from Purum Fluka] was added. This mixture was stirred for about 10 minutes before the seeds (SAPO-34 seeds) were added. The final mixture was transferred to an autoclave which was heated, while stirring, to about 160° C. with a heat-up rate of about 40° C./hr. After about 144 hours this temperature, the autoclave was cooled to approximately room temperature, and the solids were washed with demineralized water and dried at about 120° C. The yield was determined by weighing the dried solids and dividing this weight by the weight of the initial synthesis mixture. The so-calculated yield was about 8.6 wt %. The phase purity of the sample was determined by X-ray diffraction and was characterized substantially by the d-spacings shown in Table 1 above. An SEM micrograph was recorded (FIG. 14), and the average crystal size was determined to be about 0.3 μm or smaller.

Examples 15-21

A series of samples was made according to the same procedure as Example 14, but only changing the Si/Al₂ ratio of the synthesis mixture. All products resulted in materials characterized substantially by the d-spacings shown in Table 1 above, with an average crystal size of about 0.3 μm. The yield results are summarized in Table 2.

TABLE 3 Yield of products made using TMOS according to Examples 14-21 with a heat-up rate of about 40° C./hr and various Si/Al₂ ratios in the mixture. Example Si/Al₂ Yield % 14 0.11 8.6 15 0.12 9.0 16 0.13 9.1 17 0.14 10.0 18 0.15 10.6 19 0.16 11.3 20 0.17 11.9 21 0.18 12.5

Example 22

A synthesis mixture having a molar composition of about 0.15 SiO₂:P₂O₅: Al₂O₃:2 DMCHA:40 H₂O, as well as 400 wt ppm seeds, was prepared according to the following procedure. A solution of phosphoric acid was prepared by combining phosphoric acid [Acros, 85%] and water. To this solution was added the appropriate amount of Condea Pural SB [Sasol, 75.6 wt % Al₂O₃], and the slurry was stirred for about 1 hour at about 10° C. To this mixture was added the appropriate amount of tetraethylorthosilicate [TEOS, 98%, from Aldrich]. This mixture was then aged at about 10° C. while stirring for about another one hour. Then the appropriate amount of dimethylcyclohexylamine [DMCHA, 99%, from Purum Fluka] was added. This mixture was stirred for about 10 minutes before the seeds (SAPO-34 seeds) were added. The final mixture was transferred to an autoclave which was heated, while stirring, to about 170° C. with a heat-up rate of about 40° C./hr. After about 24 hours this temperature, the autoclave was cooled to approximately room temperature, and the solids were washed with demineralized water and dried at about 120° C. The yield was determined by weighing the dried solids and dividing this weight by the weight of the initial synthesis mixture. The so-calculated yield was about 11.8 wt %. SEM micrographs were recorded, and the crystal size was determined, on average, to be about 0.5 μm or smaller. The Si/Al₂ ratio in the recovered product was determined to be about 0.23. The product sieve of Example 22 was pelletized and calcined at about 600° C. for about 4 hours in air, and was then tested for its methanol-to-olefins (MTO) conversion performance under the following conditions: reaction temperature of about 500° C.; WHSV of about 100 g MeOH/g sieve/hr; and total pressure of about 25 psig (about 273 kPag). The average prime olefin selectivity (POS) was determined to be about 77.8 wt %.

Comparative Example C1

A synthesis mixture having a molar composition of about 0.15 SiO₂:P₂O₅: Al₂O₃:2 DMCHA:40 H₂O, as well as 100 wt ppm seeds, was prepared according to the following procedure. A solution of phosphoric acid was prepared by combining phosphoric acid [Acros, 85%] and water. To this solution was added the appropriate amount of Condea Pural SB [Sasol, 75.6 wt % Al₂O₃], and the slurry was stirred for about 1 hour at about 10° C. To this mixture was added the appropriate amount of Ludox AS40 [ammonium stabilized silica sol containing 40 wt % SiO₂, from Grace NV]. After about 10 minutes, the appropriate amount of dimethylcyclohexylamine [DMCHA, 99%, from Purum Fluka] was added. This mixture was stirred for about 10 minutes before the seeds (SAPO-34 seeds) were added. The final mixture was transferred to an autoclave which was heated, while stirring, to about 170° C. with a heat-up rate of about 20° C./hr. After about 48 hours this temperature, the autoclave was cooled to approximately room temperature, and the solids were washed with demineralized water and dried at about 120° C. The yield was determined by weighing the dried solids and dividing this weight by the weight of the initial synthesis mixture. The so-calculated yield was about 16.5 wt %. SEM micrographs was recorded, and the crystal size was typically about 2 μm or larger. The Si/Al₂ ratio in the recovered product was determined to be about 0.15. The product sieve of Comparative Example C1 was pelletized and calcined at about 600° C. for about 4 hours in air, and was then tested for its methanol-to-olefins (MTO) conversion performance under the following conditions: reaction temperature of about 500° C.; WHSV of about 100 g MeOH/g sieve/hr; and total pressure of about 25 psig (about 273 kPag). The average prime olefin selectivity (POS) was determined to be about 76.5 wt %.

As can be seen from the above Examples and Comparative Examples, organic silicon sources (e.g., alkoxy-functional silicates) demonstrate a distinct advantage over inorganic silicon sources (e.g., colloidal silica) in both crystal size and POS (for methanol-to-olefins reactions), though the sieve formation yields are not as high. Further, among organic silicon sources, TMOS advantageously shows slightly higher sieve formation yields with relatively similar (or slightly smaller) crystal sizes. A graphical comparison of the yield vs. Si/Al₂ ratio in synthesis mixture, taken from Tables 2-3, is presented in FIG. 5.

While the present invention has been described and illustrated by reference to particular embodiments, those of ordinary skill in the art will appreciate that the invention lends itself to variations not necessarily illustrated herein. For this reason, then, reference should be made solely to the appended claims for purposes of determining the true scope of the present invention. 

1. A method of forming an olefin-based polymer product comprising: (a) preparing a silicoaluminophosphate molecular sieve comprising; (i) combining a source of phosphorus and a source of aluminum with a liquid mixture medium to form a primary mixture, wherein said source of silicon comprises an organosilicate and said source of phosphorus comprises an organophosphate; (ii) aging the primary mixture for an aging time and under aging conditions sufficient to allow homogenization of the primary mixture, physico-chemical interaction between the source of phosphorus and the source of aluminum, or both; (iii) adding a source of silicon, N,N-dimethylcyclohexylamine organic template, and optionally additional liquid mixture medium, to the aged primary mixture to form a synthesis mixture; and (iv) inducing crystallization of a silicoaluminophosphate molecular sieve, which exhibits 90% or greater CHA framework type character, from said synthesis mixture at a crystallization temperature, wherein the crystallized silicoaluminophosphate molecular sieve has a crystal size distribution such that its average crystal size is not greater than 5 μm; (b) formulating said silicoaluminophosphate molecular sieve, along with a binder and optionally a matrix material, into a silicoaluminophosphate molecular sieve catalyst composition comprising from at least 10% to about 50% molecular sieve; (c) contacting said catalyst composition with a hydrocarbon feed under conditions sufficient to convert said hydrocarbon feed into a product comprising predominantly one or more olefins; (d) polymerizing at least one of the one or more olefins, optionally with one or more other comonomers and optionally in the presence of a polymerization catalyst, under conditions sufficient to form an olefin-based (co)polymer.
 2. The method of claim 1, wherein the hydrocarbon feed is an oxygenate-containing feed comprising methanol, dimethylether, or a combination thereof, wherein the one or more olefins comprises ethylene, propylene, or a combination thereof, and wherein the olefin-based (co)polymer is an ethylene-containing (co)polymer, a propylene-containing (co)polymer, or a copolymer, mixture, or blend thereof.
 3. The method of claim 1, wherein the crystallized silicoaluminophosphate molecular sieve exhibits a Si/Al₂ ratio not more than 0.10 greater than the Si/Al₂ ratio of the synthesis mixture.
 4. The method of claim 1, wherein said crystallization temperature is between 150° C. and 200° C.
 5. The method of claim 1, wherein the crystallized silicoaluminophosphate molecular sieve has a crystal size distribution such that the average crystal size is less than 2.0 μm.
 6. The method of claim 1, wherein the crystallized silicoaluminophosphate molecular sieve has a crystal size distribution such that the average crystal size is less than 1.2 μm.
 7. The method of claim 1, wherein the inducing step is done while stirring.
 8. The method of claim 1, wherein, within step (iii), said source of silicon is combined with said primary mixture prior to adding said at least one organic template.
 9. The method of claim 8, wherein said primary mixture and said source of silicon are combined to form a secondary mixture for a time and under conditions sufficient to allow homogenization of the secondary mixture, physico-chemical interaction between said source of silicon and said primary mixture, or both, after which said at least one organic template is combined therewith.
 10. The method of claim 1, wherein the synthesis mixture and the crystallized silicoaluminophosphate molecular sieve both exhibit a Si/Al₂ ratio less than 0.33.
 11. The method of claim 1, wherein one or more of the following are satisfied: the source of aluminum comprises alumina; the source of phosphorus comprises phosphoric acid and an organophosphate comprising a trialkylphosphate; the organosilicate comprises a tetraalkylorthosilicate; and the at least one organic template comprises N,N-dimethylcyclohexylamine.
 12. The method of claim 1, wherein the organosilicate comprises tetramethylorthosilicate, tetraethylorthosilicate, or a combination thereof.
 13. The method of claim 1, wherein step (iv) was accomplished using seeds having a framework type of CHA, AEI, AFX, LEV, an intergrowth thereof, or a combination thereof. 